Multi-layer flame retardant fabric

ABSTRACT

A composite velour fabric garment includes a laminate consisting of an outer woven shell layer, an inner thermal layer of knit construction, and an intermediate layer disposed between and laminated to each of the shell layer and the thermal layer. The outer woven shell layer contains spandex in at least a weft direction for stretch and recovery in a width direction. The knit construction of the inner thermal layer provides stretch in at least a width direction, in harmony with the shell layer, and the inner thermal layer has a raised surface facing inwardly, away from the shell layer. The intermediate layer has controlled air permeability, including zero air permeability.

This application is a continuation-in-part of U.S. application Ser. No.09/982,720, filed Oct. 18, 2001, now pending, which is acontinuation-in-part of U.S. application Ser. No. 09/883,643, filed Jun.18, 2001, now abandoned, which is a division of U.S. application Ser.No. 09/347,825, filed Jul. 2, 1999, now abandoned. The entiredisclosures of all of the aforementioned applications are incorporatedherein by reference. This application is also a continuation-in-part ofU.S. application Ser. No. 10/047,939, filed Oct. 23, 2001, now U.S. Pat.No. 6,927,182, issued Aug. 9, 2005.

TECHNICAL FIELD

This invention relates to multi-layer composite fabrics.

BACKGROUND

Multi-layer composite fabrics are achieved by joining together one ormore layers and materials in a fabric body for the purpose of attainingdesirable combinations of properties that cannot be provided by any ofthe materials or layers alone. Laminated multi-layer composites (e.g.,those having multiple layers joined, e.g., by adhesive) are frequentlyformed to enhance thermal resistance performance. Other properties canalso be enhanced through multi-layer composite fabrics.

SUMMARY

According to the invention, a composite velour fabric garment includinga laminate comprises: an outer woven shell layer comprising spandex inat least a weft direction for stretch and recovery in a width direction;an inner thermal layer of knit construction for stretch in at least awidth direction, in harmony with the shell layer, with a raised surfacefacing inwardly, away from the shell layer; and an intermediate layerhaving controlled air permeability (including zero air permeability),the intermediate layer being disposed between and laminated to each ofthe shell layer and the thermal layer.

Preferred embodiments of the invention may include one or more of thefollowing additional features. The shell layer comprises spandex in warpdirection and in weft direction for stretch and recovery in both lengthdirection and width direction, and the inner thermal layer of knitconstruction has stretch in both length direction and in widthdirection, in harmony with the shell layer. The spandex of the outershell layer comprises one or more forms of spandex selected from thegroup consisting of: bare spandex filaments, covered spandex, and airtuck spandex. The garment has good stretch and recovery. The garment hasgood flame retardant properties. Preferably, the garment has highinsulation to thermal and radiant heat. The outer shell layer comprisesflame retardant material having an L.O.I. greater than about 28.Preferably the outer shell layer comprises flame retardant fibers, e.g.formed of one or more materials selected from the group consisting of:aramides, melamines, FR polyesters, inherent flame retardant materials,and blends thereof. The inner thermal layer comprises flame retardantmaterial having an L.O.I. greater than about 28. The inner thermal layercomprises loop yarns and stitch yarns comprising flame retardantmaterials having an L.O.I. greater than about 28. Preferably, the loopyarns and the stitch yarns comprising flame retardant material serve toenhance heat and fire protection of the garment against radiant heat andflame. The inner thermal layer defines a multiplicity of predetermineddiscrete regions of contrasting insulative capacity positioned about thegarment surface, by application of body mapping principals in anarrangement having correlation to insulative requirements ofcorresponding regions of a wearer's body. Preferably, the multiplicityof discrete regions of contrasting insulative capacity positioned aboutthe garment comprise one or more selected regions of relatively lowerinsulation performance and relatively enhanced permeability createdthrough engineering knitting technology, where the selected regions haveno loop or low loop relative to surrounding regions of relatively higherloop and relatively higher insulation performance, or, alternatively,the multiplicity of discrete regions of contrasting insulative capacitypositioned about the garment comprise one or more selected regions ofrelatively lower insulation performance and relatively enhancedpermeability created through engineering printing technology, where theselected regions have a coating of binder material causing the selectedregions to resist raising relative to surrounding relatively raisedregions of relatively higher insulation performance. The intermediatelayer having predetermined air permeability is selected from the groupconsisting of: foamed adhesive in a discontinuous film, adhesive in acontinuous film mechanically altered by a process of crushing andstretching, breathable adhesive in a discontinuous film, and a membranemechanically altered by a process of stretching and perforation. Thebreathable adhesive comprises a flame retardant polymer. Preferably, theflame retardant polymer comprises a polymeric material having an L.O.I.at or above about 28. The flame retardant polymer comprises one or moreflame retarding additives. The intermediate layer has controlled airpermeability in the range of about 0 CFM to about 100 CFM, andpreferably in the range of about 3 CFM to about 10 CFM. The intermediatelayer having predetermined air permeability has zero air permeability.The intermediate layer comprises a full film breathable membrane.Preferably, the full film breathable membrane of the intermediate layeris formed of a material selected from the group consisting of:polyurethane, polyetherester, EPTFE (stretchable poly tetra fluoroethylene), and SPM (selective permeable membrane). One or more regionsof an outer surface of the outer shell layer has a continuous or anoncontinuous coating comprising an abrading resistant material. One ormore regions of an outer surface of the outer shell layer has acontinuous or a noncontinuous coating comprising a pilling resistantmaterial. One or more regions of an outer surface of the outer shelllayer has a continuous or a noncontinuous coating comprising awater-repelling material. The outer shell layer is formed of a materialhaving anti-static properties. One or more regions of the garment hasgood hydrostatic resistance. One or more regions of the garment has highmoisture vapor transmission in static conditions and in dynamicconditions. One or more regions of the outer surface of the outer shelllayer has a non-continuous or continuous coating comprising discretecoating segments of coating material applied to bind individual yarnfibers together for enhanced abrasion resistance performance. Thediscrete coating segments of coating materials comprise discrete dots.One or more regions of an outer surface region of the outer shell layerhas a non-continuous coating of binder material adhered at least atinterlacing intersections for enhanced durability performance againstpilling or fraying. Adhering binder material is limited in a manner tosubstantially avoid restriction of air permeability through thecomposite velour fabric garment.

The details of one or more embodiments of the invention are set forth inthe accompanying drawings and the description below. Other features,objects, and advantages of the invention will be apparent from thedescription and drawings, and from the claims.

DESCRIPTION OF DRAWINGS

FIG. 1 is a cross-sectional view of a multi-layer composite fabric ofthe invention.

FIG. 2 is a perspective view of another embodiment of a multi-layercomposite fabric of the invention having a pattern of raised surfaceregions formed on the inner surface of the inner thermal fabric layer.

FIG. 3 is a perspective view of another embodiment of a multi-layercomposite fabric of the invention having regions of no loop or low loop,or otherwise unraised surface, disposed selectively about a raisedsurface formed on the inner surface of the inner thermal fabric layer.

Like reference symbols in the various drawings indicate like elements.

DETAILED DESCRIPTION

Referring to FIG. 1, a multi-layer composite fabric laminate 20 of theinvention provides flame retardance and improved dynamic insulationperformance in a velour fabric article. The composite fabric laminate 20consists of an outer shell 22 formed, e.g., of woven fabric, and aninner thermal layer 24 formed, e.g., of knit construction, both beinglaminated to an intermediate, air-permeable or air impermeable barrierlayer 26 disposed therebetween. The barrier layer is formed, e.g., of adiscontinuous or continuous member or layer of adhesive to permitcontrolled air permeability (including zero air permeability). Thecomponents of the composite fabric laminate are formed of flameretardant materials and/or additives to provide flame retardantproperties. In fact, the laminate is preferably almostself-extinguishing. In addition, the composite fabric laminate 20 hasthe properties of high moisture vapor transmission in static and dynamicconditions, good stretch and recovery, good hydrostatic resistance, e.g.as determined in accordance with ASTM D-751, i.e. by pressureapplication by a rising column of water, the complete disclosure ofwhich test method is incorporated herein by reference, and highinsulation to thermal and radiant heat.

Woven Outer Shell (22)

In preferred embodiments, the woven outer shell 22 contains spandex inthe warp and weft directions, for two-way stretch, i.e. in the lengthand width directions. Alternatively, the shell may contain spandex onlyin the weft direction, for one-way stretch, i.e. mainly in the widthdirection. The spandex contained by the stretchable woven fabric shellmay be in the form of bare spandex filaments, covered spandex, air tuckspandex, or as otherwise suited to the fabric construction. The wovenfabric shell is thus provided with characteristics of good stretch andrecovery. It may also have the characteristics of high abrasionresistance, e.g. as determined in accordance with ASTM D-3884; highpilling resistance, e.g. as determined in accordance with ASTM D-3512;very good water repellence, e.g. as determined in accordance with AATCC22-1980; and good antistatic properties. The complete disclosures of allof these test methods are enclosed herein by reference. Methods andprocedures for achieving desired levels of abrasion resistance andpilling resistance according to the invention are described, e.g., inU.S. patent application Ser. No. 10/700,405, filed Nov. 4, 2003; U.S.Provisional Patent Application No. 60/493,275, filed Aug. 7, 2003; andU.S. patent application Ser. No. 10/911,855, Aug. 5, 2004, the completedisclosures of all of which are incorporated herein by reference.

The woven fabric shell 22 may also be formed of, and/or incorporate,fibers of flame retardant materials, such as aramides, e.g. as soldunder the trademark NOMEX® by E.I. du Pont de Nemours and Co., Inc., ofWilmington, Del., or blends of fibers, such as NOMEX® (aramide fibers),KEVLAR® (para-aramide fibers, also available from E.I. du Pont), andanti-static fibers. As used herein, the term flame-retardant refers tofabrics and other materials that, due to chemical treatment or inherentproperties, do not ignite readily or propagate flaming undersmall-to-moderate fire exposure. See, e.g., Fire Protection Handbook(17^(th) Edition), National Fire Protection Association, Quincy, Mass.,1992. (p. 3-174), the complete disclosure of which is incorporatedherein by reference.

Inner Thermal Fabric Layer (24)

The inner thermal layer 24 is formed of a knit construction with aninner surface 28 facing the wearer's body. The sinker loop yarns of theinner surface may be raised and finished, e.g. in velour or shearling,or as terry loop. The knit construction of the inner thermal layerprovides two-way stretch, i.e. in the length and width directions or,alternatively, it may only provide for one-way stretch, i.e. mainly inthe width direction. In either case, the stretch and recovery of theinner thermal layer 24 and the outer shell 22 are in harmony, i.e., bydesign, a two-way stretch outer shell will be laminated with a two-waystretch inner thermal layer and a one-way stretch outer shell will belaminated with a one-way stretch inner thermal layer.

The inner thermal fabric layer 24 may also be formed of, and/orincorporate, fibers of flame retardant materials, such as aramides, e.g.as sold under the trademark NOMEX® by E.I. du Pont de Nemours and Co.,Inc., of Wilmington, Del. or under the trademark PBI® by CelaneseAdvanced Materials, Inc. of Charlotte, N.C.; melamine e.g. as sold underthe trademark BASOFIL® by Basofil Fibers, LLC of Charlotte, N.C.; FR(“flame retardant”) polyester, or other suitable materials. The pileheight of the raised fibers of inner surface 28 determines theinsulation properties of the composite laminate fabric 20, and, in thecase of flame retardant material being incorporated in the loop yarn andstitch yarn, the height will also determine the level of radiant heatand fire protection provided against radiant heat and flame.

Referring to FIG. 2, in another embodiment of a multi-layer compositefabric laminate 30, the sinker loop construction of inner surface 34 orthe inner thermal fabric layer 32 may have the form of a pattern, suchas grid, box, etc., selected to generate a channeling effect, e.g. asdescribed in U.S. application Ser. No. 10/047,939, filed Oct. 23, 2001,the complete disclosure of which is incorporated herein by reference.For example, the inner thermal fabric layer 32 can include a pluralityof vertical and horizontal channels 38 between fiber pillars 36 (i.e.,discrete pillar regions of sinker loop yarn) as illustrated in FIG. 2.The plurality of channels formed along the inner fabric layerfacilitates maintaining a cushion of air along the skin for added warmthduring static physical conditions and enhanced air flow during physicalactivity, thereby creating a heat dissipating or cooling effect. Theresulting fabric has relatively reduced weight but still maintains arelatively high level of thermal and radiant heat insulation.

Referring to FIG. 3, in still another embodiment of a multi-layercomposite fabric laminate 40, the inner surface 42 of the inner thermalfabric layer 44 may have regions 46 of low loop or no loop, or otherwiseremaining unraised, disposed among relatively raised regions 48. Thearrangement of the respective regions 46, 48 is determined according toprinciples of body mapping, with the regions 46 of low loop or no loopbeing positioned to generally overlie surfaces of the wearer's bodyrequiring relatively low insulation and relatively high airpermeability, e.g. in the wearer's armpit area, and raised regions 48 ofsurface 42 being positioned to generally overlie surfaces of thewearer's body requiring relatively more insulation and relatively lesspermeability. These body mapping arrangements may be achieved, e.g.,through engineering knitting, where selected regions 46 or low loop orno loop are formed (as described, e.g., in U.S. Provisional ApplicationNo. 60/582,674, filed Jun. 24, 2004; in U.S. Provisional Application No.60/605,563, filed Aug. 30, 2004; and in U.S. Provisional Application No.60/626,191, filed Nov. 9, 2004, the complete disclosures of all of whichare incorporated herein by reference). Alternatively, the mappingarrangements may be achieved, e.g., through engineering printingtechnology, where selected regions 46 requiring relatively lessinsulation and more permeability are coated with a binder material tocause the regions to resist raising (as described in U.S. ProvisionalApplication No. 60/493,275, filed Aug. 7, 2003, in U.S. application No.10/911,855, filed Aug. 5, 2004, the complete disclosures of all of whichare incorporated herein by reference).

Intermediate Breathable Barrier Layer (26)

The intermediate barrier layer 26 importantly provides controlled airpermeability (including zero permeability), e.g. in the range of about 0CFM to about 100 CFM, and preferably in the range of about 3 CFM toabout 10 CFM, as determined in accordance with ASTM D-737, the completedisclosure of which is incorporated herein by reference. The controlledair permeability of the breathable film serves to enhance the comfortlevel afforded to the wearer in dynamic conditions, where permeation byambient air cools down the wearer by reducing the level of moisturevapor in the micro climate between the outer shell fabric 22 and thewearer's skin, and enhances the cooling down effect by increasing theheat of evaporation and convection heat loss.

The breathable intermediate barrier may have the form of anon-continuous, breathable film, or it may have the form of anon-continuous adhesive layer formed without a film, or it may have theform of an adhesive layer formed as a full layer, without a film, whichis subsequently crushed to create a non-continuous layer. Methods andmaterials for forming a typical breathable intermediate barrier suitablefor use in a composite fabric laminate 20 of the invention aredescribed, e.g., in U.S. patent application Ser. No. 10/650,098, filedAug. 25, 2003, the complete disclosure of which is incorporated hereinby reference. The intermediate barrier, whether non-continuous film oradhesive, may also have flame retardant properties provided by selectionof flame retardant polymeric materials having a Limiting Oxygen Index(“L.O.I.”) over 28, and/or by selection of flame retardant additives.

In other embodiments, e.g. where the fabric is intended for use, e.g.,by firefighters or helicopter crews performing emergency rescues aboveor in bodies of water, the intermediate barrier may be formed of a fullfilm breathable membrane formed of a material such as polyurethane,polyetherester, EPTFE (stretchable poly tetra fluoro ethylene), SPM(selective permeable membrane), etc. In such cases, the intermediatebarrier may be impermeable, with controlled air permeability of 0 CFM inboth static and dynamic conditions.

A number of embodiments of the invention have been described.Nevertheless, it will be understood that various modifications may bemade without departing from the spirit and scope of the invention.

1. A composite velour fabric garment including a laminate comprising: anouter woven shell layer comprising spandex in at least a weft directionfor stretch and recovery in a width direction; an inner thermal layer ofknit construction for stretch in at least a width direction, in harmonywith the shell layer, with a raised surface facing inwardly, away fromthe shell layer, the raised surface including: one or more regions oflow loop or no loop being positioned to generally overlie surfaces ofthe wearer's body requiring relatively low insulation; and one or moreother regions of relatively higher loop positioned to generally overliesurfaces of the wearer's body requiring relatively more insulation; andan intermediate layer having controlled air permeability, saidintermediate layer being disposed between and laminated to each of theshell layer and the thermal layer, wherein one or more of the outer,inner, and intermediate layers comprises flame retardant material. 2.The composite velour fabric garment of claim 1, wherein the shell layercomprises spandex in warp direction and in weft direction for stretchand recovery in both length direction and width direction, and the innerthermal layer of knit construction has stretch in both length directionand in width direction, in harmony with the shell layer.
 3. Thecomposite velour fabric garment of claim 1 or claim 2, wherein thespandex of the outer shell layer comprises one or more forms of spandexselected from the group consisting of: bare spandex filaments, coveredspandex, and air tuck spandex.
 4. The composite velour fabric garment ofclaim 1 or claim 2, wherein the garment has good stretch and recovery.5. The composite velour fabric garment of claim 1, wherein the garmenthas good flame retardant properties.
 6. The composite velour fabricgarment of claim 5, wherein the garment has high insulation to thermaland radiant heat.
 7. The composite velour fabric garment of claim 5,wherein the outer shell layer comprises flame retardant material havingan L.O.I. greater than about
 28. 8. The composite velour fabric garmentof claim 7, wherein the outer shell layer comprises flame retardantfibers.
 9. The composite velour fabric garment of claim 8, wherein theflame retardant fibers are formed of one or more materials selected fromthe group consisting of: aramides, melamines, FR polyesters, inherentflame retardant materials, and blends thereof.
 10. The composite velourfabric garment of claim 5, wherein the inner thermal layer comprisesflame retardant material having an L.O.I. greater than about
 28. 11. Thecomposite velour fabric garment of claim 10, wherein the inner thermallayer comprises loop yarns and stitch yarns comprising flame retardantmaterials having an L.O.I. greater than about
 28. 12. The compositevelour fabric garment of claim 11, wherein the loop yarns and the stitchyarns comprise flame retardant material that serve to enhance heat andfire protection of the garment against radiant heat and flame.
 13. Thecomposite velour fabric garment of claim 1, wherein the intermediatelayer having predetermined air permeability is selected from the groupconsisting of: foamed adhesive in a discontinuous film, adhesive in acontinuous film mechanically altered by a process of crushing andstretching, breathable adhesive in a discontinuous film, and a membranemechanically altered by a process of stretching and perforation.
 14. Thecomposite velour fabric garment of claim 13, wherein the breathableadhesive comprises a flame retardant polymer.
 15. The composite velourfabric garment of claim 14, wherein the flame retardant polymercomprises a polymeric material having an L.O.I. at or above about 28.16. The composite velour fabric garment of claim 14 or claim 15, whereinthe flame retardant polymer comprises one or more flame retardingadditives.
 17. The composite velour fabric garment of claim 1 or claim13, wherein the intermediate layer has controlled air permeability inthe range of about 0 CFM to about 100 CFM.
 18. The composite velourfabric garment of claim 17, wherein the intermediate layer hascontrolled air permeability in the range of about 3 CFM to about 10 CFM.19. The composite velour fabric garment of claim 1, wherein saidintermediate layer having predetermined air permeability has zero airpermeability.
 20. The composite velour fabric garment of claim 19,wherein said intermediate layer comprises a full film breathablemembrane.
 21. The composite velour fabric garment of claim 20, whereinsaid full film breathable membrane of said intermediate layer is formedof a material selected from the group consisting of: polyurethane,polyetherester, EPTFE (stretchable poly tetra fluoro ethylene), and SPM(selective permeable membrane).
 22. The composite velour fabric garmentof claim 1, wherein one or more regions of an outer surface of the outershell layer has a continuous or a noncontinuous coating comprising anabrading resistant material.
 23. The composite velour fabric garment ofclaim 1, wherein one or more regions of an outer surface of the outershell layer has a continuous or a noncontinuous coating comprising apilling resistant material.
 24. The composite velour fabric garment ofclaim 1, wherein one or more regions of an outer surface of the outershell layer has a continuous or a noncontinuous coating comprising awater-repelling material.
 25. The composite velour fabric garment ofclaim 1, wherein the outer shell layer is formed of a material havinganti-static properties.
 26. The composite velour fabric garment of claim1, wherein one or more regions of the garment has good hydrostaticresistance.
 27. The composite velour fabric garment of claim 1, whereinone or more regions of the garment has high moisture vapor transmissionin static conditions and in dynamic conditions.
 28. The composite velourfabric garment of claim 1, wherein one or more regions of the outersurface of the outer shell layer has a non-continuous or continuouscoating comprising discrete coating segments of coating material appliedto bind individual yarn fibers together for enhanced abrasion resistanceperformance.
 29. The composite velour fabric garment of claim 28,wherein the discrete coating segments of coating materials comprisediscrete dots.
 30. The composite velour fabric garment of claim 1,wherein one or more regions of an outer surface region of the outershell layer has a non-continuous coating of binder material adhered atleast at interlacing intersections for enhanced durability performanceagainst pilling or fraying.
 31. The composite velour fabric garment ofclaim 30, wherein adhering binder material is limited in a manner tosubstantially avoid restriction of air permeability through thecomposite velour fabric garment.
 32. The composite velour fabric garmentof claim 1, wherein the inner thermal layer comprises loop yarnscomprising flame retardant material.
 33. A composite velour fabricgarment including a laminate comprising: an outer woven shell layercomprising spandex in at least a weft direction for stretch and recoveryin a width direction; an inner thermal layer of knit construction forstretch in at least a width direction, in harmony with the shell layer,with a raised surface facing inwardly, away from the shell layer, theraised surface including: a plurality of discrete pillar regions ofsinker loop yarn arranged in a grid or box pattern and configured toform a plurality of intersecting channels between a wearer's body andthe inner thermal layer; and an intermediate layer having controlled airpermeability, said intermediate layer being disposed between andlaminated to each of the shell layer and the thermal layer, wherein oneor more of the outer, inner, and intermediate layers comprises flameretardant material.